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Summary of Contents for Reflex Servitec 30
- Page 1 06.07.2016 - Rev. B Vacuum spray degassing Servitec 30 Operating manual Original operating manual...
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Page 3: Table Of Contents
Contents English Vacuum sp ray d egassing 06.07.2016 - Rev. B Contents Notes on the operating manual..............................5 Liability and guarantee................................... 5 Safety........................................ 6 Explanation of symbols ..................................6 Personnel requirements ..................................7 Personal protective equipment ................................7 Intended use ......................................7 Inadmissible operating conditions.............................. - Page 4 Cleaning the dirt trap ..............................49 10.3 Maintenance certificate ..................................50 Disassembly ....................................51 Annex ......................................53 12.1 Reflex Customer Service ..................................53 12.2 Conformity and standards ................................. 54 12.3 Guarantee ......................................55 4 — English Vacuum spray degassing — 06.07.2016 - Rev. B...
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Page 5: Notes On The Operating Manual
Reflex Winkelmann GmbH accepts no liability for any damage resulting from failure to observe the information in this operating manual. In addition to the requirements set out in this operating manual, national statutory regulations and provisions in the country of installation must also be complied with (concerning accident prevention, environment protection, safe and professional work practices, etc.). -
Page 6: Safety
Safety Safety Explanation of symbols The following symbols and signal words are used in this operating manual. DANGER Danger of death and/or serious damage to health • The sign, in combination with the signal word 'Danger', indicates imminent danger; failure to observe the safety information will result in death or severe (irreversible) injuries. -
Page 7: Personnel Requirements
Safety Personnel requirements Only specialist personnel or specifically trained personnel may install and operate the equipment. The electric connections and the wiring of the device must be executed by a specialist in accordance with all applicable national and local regulations. Personal protective equipment When working at the system, wear the stipulated personal equipment such as hearing and eye protection, safety boots, helmet, protective clothing, protective gloves. -
Page 8: Residual Risks
Safety Residual risks This device has been manufactured to the current state of the art. However, some residual risk cannot be excluded. CAUTION Risk of burns on hot surfaces Hot surfaces in heating systems can cause burns to the skin. •... -
Page 9: Description Of The Device
Description of the device Description of the device Description The device is a degassing and make-up station. Its main areas of application are heating and cooling circuits and systems in which interruptions of operations due to dissolved or free gases. The device works only with a vacuum pump designed for this purpose. This design enables a compact footprint for small and mid-sized systems. -
Page 10: Identification
Description of the device Identification The nameplate provides information about the manufacturer, the year of manufacture, the manufacturing number and the technical data. Information on nameplate Meaning Type Device name Serial No. Serial number min. / max. allowable pressure P Minimum/maximum permissible pressure max. - Page 11 Description of the device Degassing cycle sequence in the PU vacuum pump Cooling water system ≤ 30 °C, System pressure 1.8 bar, "DC" system degassing in operation, "WC" make-up degassing closed. Vacuum is drawn Discharge Atomisation Idling time Degassing The entire degassing process is hydraulically synchronised by the "CD" 3-ways motor ball valve and the device controller. The system monitors the operating states and displays them at the controller.
- Page 12 Description of the device Make-up variants There are two make-up variants. Both are monitored via the make-up time and the make-up cycles. "WC" make-up line "DC" degassing line (degassed water to the facility system) Optional add-on device (see Chapter Optional "DC"...
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Page 13: Scope Of Delivery
Description of the device Scope of delivery The scope of delivery is described in the shipping document for the initial shipment and the content is shown on the packaging. Immediately after receipt of the goods, please check the shipment for completeness and damage. Please notify us immediately of any transport damage. -
Page 14: Technical Data
Technical data Technical data Note! The following values apply for all systems: – Permissible flow temperature: 120 °C – Permissible operating temperature makeup 0 °C – 30 °C degassing: 0 °C – 45 °C – Permissible ambient temperature: 8 bar –... - Page 15 Technical data Approximate values for the maximal "Va" system volume to be degassed under extreme conditions during commissioning at a nitrogen reduction from 18 mg/l to 10 mg/l. Continuous degassing "t" System volume "Va" [m Vacuum spray degassing — 06.07.2016 - Rev. B English —...
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Page 16: Installation
Confirm that installation and start-up have been carried out correctly using the installation, start-up and maintenance certificate. This action is a prerequisite for the making of warranty claims. – Have the Reflex Customer Service carry out commissioning and the annual maintenance. 16 — English Vacuum spray degassing — 06.07.2016 - Rev. B... -
Page 17: Installation Conditions
Installation Installation conditions 6.1.1 Incoming inspection Prior to shipping, this device was carefully inspected and packed. Damages during transport cannot be excluded. Proceed as follows: Upon receipt of the goods, check the shipment for • completeness and • possible transport damage. 2. -
Page 18: Execution
Installation Execution CAUTION Risk of injury due to tipping over of the device Risk of bruising or crushing caused by tipping over of the device • Ensure sufficient stability of the device. • Weigh down the bearing surface of the device's transport unit with suitable means. Note! The screw connections at the device may loosen when the device is moved to another location. -
Page 19: Fitting The Add-On Components
Installation 6.3.1 Fitting the add-on components Install the ball valves at the device. Attach the ball valve for the "WC" make-up connection. – If you don't connect the automatic make-up, close the "WC" connection with a G ½ " blind plug. Attach the ball valve with the "ST"... -
Page 20: Hydraulic Connection
Installation 6.3.3 Hydraulic connection 6.3.3.1 Degassing line to the system Installation detail of the "DC" degassing line Install the 'DC' degassing pipes as shown below: Proceed as follows: • Prevent an overload of the "ST" dirt trap in the device caused by coarse dirt. •... - Page 21 Installation Device installation in a heating system – Pressure maintenance with diaphragm-type "MAG" expansion tank Heating system Device Pressure expansion tank "DC" degassing line (gas-rich water) For optional equipment and accessories, see chapter 4.6 "DC" degassing line (degassed water) "Optional equipment and accessories" on page 13 Proceed as follows: •...
- Page 22 Installation 6.3.3.2 Make-up line "ST" dirt trap Device "BT" system separator vessel "DC" degassing line (gas-rich water) "WC" makeup line "DC" degassing line (degassed water) For water makeup, note the following conditions: • For a water makeup via a "BT" mains disconnect receptacle, its bottom edge must be at least 100 mm over the "PU" device pump. •...
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Page 23: Switching And Make-Up Variants
Installation Switching and make-up variants Select the make-up variant in the Customer menu of the device controller, see chapter 9.5 "Parametrising the controller in the Customer menu" on page 40 . Choose from one of the following make-up variants in the Customer menu: •... -
Page 24: Level Dependent "Levelcontrol" Make-Up Mode
Installation 6.4.2 Level dependent "Levelcontrol" make-up mode The device is in "Levelcontrol" operating mode which is used for systems with pressure maintenance stations. Pressure maintaining station Device "WC" make-up line "DC" degassing line (degassed water) For optional equipment and accessories, see chapter 4.6 "DC"... -
Page 25: Electrical Connection
Installation Electrical connection DANGER Risk of serious injury or death due to electric shock. If live parts are touched, there is risk of life-threatening injuries. • Ensure that the system is voltage-free before installing the device. • Ensure that the system is secured and cannot be reactivated by other persons. •... -
Page 26: Terminal Diagram
Installation 6.5.1 Terminal diagram "L" fuse for electronics and solenoid valves Digital inputs • Water meter • Insufficient water "N" fuse for solenoid valves "CD" 3-ways motor ball valve Overflow valve (not for motor ball valve) Pressure analogue input Group message External makeup demand (Levelcontrol only) Optional for second pressure value Makeup valve... - Page 27 Installation Terminal Signal Function Wiring number 230 V power supply via mains cable and plug. Pre-wired "PU" vacuum pump for degassing. Pre-wired 6 M1 Overflow solenoid valve Not used in standard model "CD" 3-ways motor ball valve for regulating the degassing of makeup Pre-wired and system water.
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Page 28: Rs-485 Interface
All messages, see chapter 9.6 "Messages" on page 44 . • All entries in the fault memory. Note! If required, please contact the Reflex Customer Service for the protocol of the RS-485 interface, details of the connections and information about the accessories offered. 6.5.2.1 Connecting the RS-485 interface... -
Page 29: Installation And Commissioning Certificate
Installation Installation and commissioning certificate Data shown on the nameplate: Type: Serial number: This device has been installed and commissioned in accordance to the instructions provided in the Operating Manual. The settings in the controller match the local conditions. Note! When any factory-set values of the device are changed, you must enter this information in the Maintenance certificate, see chapter 10.3 "Maintenance certificate "... -
Page 30: Commissioning
This action is a prerequisite for the making of warranty claims. – Have the Reflex Customer Service carry out commissioning and the annual maintenance. Checking the requirements for commissioning The device will be ready for commissioning when the tasks described in the "Installation" chapter have been completed. -
Page 31: Filling The Device With Water
Commissioning Filling the device with water Use the system to fill water into the device. Open the "CD" 3-ways motor ball valve to the system. Start turning the "PU" vacuum pump at the fan wheel using a screw driver. CAUTION – Injuries caused by pump start-up. Hand injury due to a pump start. -
Page 32: Modifying The Controller's Start Routine
Commissioning Modifying the controller's start routine The start routine enables the setting of the essential parameters required for the device's commissioning. It commences with the first activation of the controller and can be run only once. Parameters can be changed or checked in the customer after the start routine has terminated see chapter 9.5 "Parametrising the controller in the Customer menu"... -
Page 33: Starting Automatic Mode
Commissioning Starting Automatic mode Automatic mode can be started as soon as the system is filled with water and the gases contained have been vented. • Press "Auto" on the controller's operator panel. During commissioning, continuous degassing is automatically activated to remove any residual free or dissolved gases from the system. This time can be set in the Customer menu as required by the system conditions. -
Page 34: Operation
Operation Operation Operating modes 8.1.1 Automatic mode Upon successful commissioning, you can activate the automatic mode with the degassing functions and, optionally, the automatic make-up. The device controller monitors the functions. Faults are displayed and evaluated. For automatic mode, you can set three different degassing programmes in the Customer menu, see chapter 9.5 "Parametrising the controller in the Customer menu"... -
Page 35: Manual Mode
Operation 8.1.2 Manual mode The manual mode is intended for test and service tasks. Press "Manual" at the controller. The Auto LED at the operator panel flashes to visually indicate that manual mode is active. In manual mode, you manually switch the "PU" vacuum pump and the "CD" 3-ways motor ball valve. Both can be switched after each other and tested at the same time. -
Page 36: Summer Operation
Operation 8.1.4 Summer operation The degassing of the network water is not assured if the circulating pumps of the system are shut down during Summer because gas-rich water cannot reach the device. In order to save energy, use the Customer menu to set the degassing programme to make-up degassing. If the device is operated with make-up degassing during Summer, you must switch to interval or continuous degassing after the circulating pumps have been activated. -
Page 37: Controller
Controller Controller Operator panel Error LED "Back" to the previous menu • The Error LED illuminates in the event of a fault Display Auto • For continuous operation Auto LED "Forward" to the next menu • The Auto LED illuminates green in Automatic mode •... -
Page 38: Customer Menu
Service menu This menu is protected with a password. It can be accessed only by the Reflex Customer Service. A partial summary of the settings stored in the Service menu is proved in the Chapter Default settings, see chapter 9.4 "Default settings" on page 39 . -
Page 39: Default Settings
Controller Default settings The device controller is shipped with the following default settings. Use the Customer menu to adjust these values to local conditions. In specific cases, it is possible to further adjust the values in the Service menu. Customer menu Parameter Setting Remarks... -
Page 40: Parametrising The Controller In The Customer Menu
Change the flashing display items for "Day", "Month", and "Year" to the current date. Date: The date of an alarm will be stored in the fault memory. Magcontrol: Servitec 30: Select this setting if you want to realise a pressure-dependent automatic make-up in system with diaphragm expansion tank. Levelcontrol: Select this setting if you want to realise a level-dependent make-up in system with pressure maintenance station. - Page 41 Controller Time setting for Continuous degassing. Time Continuous. degas. – For commissioning, we recommend to set the time for continuous degassing depending on the system volume and the glycol content, see chapter 5.3 "Operation" on page 14 . Switch to the "Make-up" sub-menu. Make-up Switch to the next list item.
- Page 42 Controller Only displayed if "YES" has been set in the "With softening" menu option. Hardness reduction Is calculated from the difference of the overall water hardness GH and the target water actual hardness GH as defined by the manufacturer specification: target Hardness reduction = GH l °dH...
- Page 43 Switch to the parameter memory or into the next main menu option. Parameter memory The last 10 entries of the minimum working pressure are stored with date and time. P0 = xx.x bar Information about the software version. Servitec 30 Vacuum spray degassing — 06.07.2016 - Rev. B English — 43...
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Page 44: Messages
The fault memory stores the last 20 alarms for review, see chapter 9.5 "Parametrising the controller in the Customer menu" on page 40 . Alarm causes can be eliminated by the operator or a specialist workshop. Please contact the Reflex customer service for alarms that cannot be repaired. - Page 45 Controller ER Code Alarm Floating contact Cause Remedy Alarm reset Makeup time • Set value exceeded. • Check set value in the Quit Customer or Service • Water loss in the system menu. • Makeup line not connected. • Check water level. •...
- Page 46 • Option card defective. and controller. • Replace the option card. EEPROM defective • EEPROM defective. Inform Reflex Customer Quit Service. • Internal calculation error. Undervoltage Supply voltage not achieved. Check power supply. Adjustment EPROM parameter memory...
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Page 47: Maintenance
The annual maintenance is displayed upon expiry of the set operating time. Use "Quit" to acknowledge the "Maintenance recommended" message. Note! Maintenance work must be carried out and confirmed by specialist personnel or the Reflex Customer Service. Vacuum spray degassing — 06.07.2016 - Rev. B English — 47... -
Page 48: Maintenance Schedule
Maintenance 10.1 Maintenance schedule The maintenance schedule is a summary of maintenance tasks to be carried out regularly. Maintenance task Conditions Interval ▲ = Check, ■ = Service, ● = Clean ▲ ■ Check for leaks. Annually • "PU" vacuum pump •... -
Page 49: Cleaning
Maintenance 10.2 Cleaning 10.2.1 Cleaning the dirt trap The "ST" dirt trap in the "DC" degassing line must be cleaned after the expiry of the continuous degassing time at the latest. Check the dirt traps after every filling action or extended operation. Press "Stop"... -
Page 50: Maintenance Certificate
Maintenance 10.3 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation, Operating and Maintenance Manual. Date Service organisation Signature Remarks 50 — English Vacuum spray degassing — 06.07.2016 - Rev. B... -
Page 51: Disassembly
Disassembly Disassembly DANGER Risk of serious injury or death due to electric shock. If live parts are touched, there is risk of life-threatening injuries. • Ensure that the system is voltage-free before installing the device. • Ensure that the system is secured and cannot be reactivated by other persons. •... - Page 52 Disassembly Prior to the disassembly, lock out the "DC" degassing lines and the "WC" makeup line from the system and de-pressurise the device. Then disconnect the device from all electrical power sources. Disconnect the system from the power supply and secure it against unintended reactivation. Lock out the "DC"...
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Page 53: Annex
Annex Annex 12.1 Reflex Customer Service Central customer service Central telephone number: +49 (0)2382 7069 - 0 Customer Service extension: +49 (0)2382 7069 - 9505 Fax: +49 (0)2382 7069 - 9588 E-mail: service@reflex.de Technical Hotline For questions about our products... -
Page 54: Conformity And Standards
Register No. of the notified body 0045 Manufacturer The manufacturer declares that the pressure equipment (the tank / the assembly) complies with the requirements of Directive 2014/68/EU. Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen - Germany Telephone: +49 2382 7069 -0 Norbert Hülsmann... -
Page 55: Guarantee
Annex 12.3 Guarantee The respective statutory guarantee regulations apply. Vacuum spray degassing — 06.07.2016 - Rev. B English — 55... - Page 56 Annex 56 — English Vacuum spray degassing — 06.07.2016 - Rev. B...
- Page 58 Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen, Germany Telefon: +49 (0)2382 7069-0 Telefax: +49 (0)2382 7069-9588 www.reflex.de...
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